Group 04 Engine Rebuild Guide 6076 ENGINE DISASSEMBLY SEQUENCE The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group when removing individual engine components. 15. Remove exhaust manifold and air intake manifold. 16. Remove turbocharger oil return line. 17. Remove cylinder head with valve assembly. Remove head gasket. NOTE: Remove starting motor before mounting engine into repair stand. 1. Drain all coolant and engine oil. Check engine oil for metal contaminates. 18. On SAE No. 3 flywheel housings, remove flywheel then remove flywheel housing. 2. Remove turbocharger oil inlet line. 19. On SAE No.
1 and 2 flywheel housings, remove flywheel housing and then remove flywheel. 3. Remove breather hose. 20. Roll engine over and remove oil pan and engine oil pump assembly. 04 1 4. Remove fan pulley and water manifold assembly. 21. Remove front timing gear cover. 5. Remove turbocharger exhaust elbow and connector. Remove turbocharger. 22. Rotate engine to vertical position. Remove pistons and connecting rods. Identify for re-assembly. Perform wear checks with PLASTIGAGE™. NOTE: DO NOT damage option code label (if equipped), when removing rocker arm cover. 6. Remove rocker arm cover. NOTE: Perform wear check on main bearing surfaces with PLASTIGAGE, when removing main bearing caps. 7.
Remove rocker arm assembly and push rods. Identify parts for re-assembly. 23. Remove main bearing caps. Remove crankshaft and main bearings. Identify for re-assembly. 8. Remove alternator and mounting brackets. 24. Remove camshaft and cam followers. Identify for re-assembly. 9. Remove front crankshaft pulley and damper assembly. 10. Remove fuel injection lines and injection nozzles. 25. Rotate engine and remove liners and their O-ring seals. Mark liners for reassembly in same bore from which removed. 11. Remove water pump. 26. Remove piston cooling orifices. 12. Remove engine oil filter and oil conditioning housing. 27.
Remove cylinder block plugs and engine serial number plate, if block is to be put in a “hot tank”. 13. Remove injection pump gear cover and remove injection pump. Remove fuel filter and mounting base. 28. Refer to appropriate group for inspection and repair of engine components. 14. On 6076A Engines, remove aftercooler cover and aftercooler assembly. PLASTIGAGE™ is a trademark of the Perfect Circle Division of Dana Corp. RG,CTM42,G4,1 -19-24SEP91 CTM42 (24MAR95) 04-1 6076 Diesel Engines—S.N. (500000— ) 160101 PN=40